Many researches[1]~[6] indicate that both mold temperature and injection

temperature are important factors making profound influence on injection

molding parts. Therefore, in our case study, we focus on the effects of
changing two parameters and the simulation is performed by Autodesk
Simulation Moldflow Advisor 2015. To give a quick validation of the software,
we compare the location of weld lines in realistic part and virtual results since
weld lines is one of the most visualized and inevitable defects. Figure 1
indicates that the prediction in weld line position matches the real situation.

a.

b.

c.

Figure 1- prediction of weld lines position in Moldflow matches the real

situation. (a) the result of simulation shows two local weld lines A and B.
(b)Weld line A in real part. (c) Weld line B in the real part.
Effects of Melt Temperature on Defects Formation
Melt temperature is also a key process parameter. Parts quality, fill time of
the polymer melt, and several defects formation are closely related to it
(Yang, et al. 2004). Polymer melt temperature affects the injection pressure
and filling time through fluid viscosity and thermodynamics, and therefore
has strong influence on the formation of shrinkage and weld lines.
In our study, weld lines were quantified as weld line angle, which is the angle
of the weld line gap. This gap angle indicates the depth of the gap; smaller
the angle, deeper the gap. Thus, a large gap angle is favored. Specifically in

the case study of the fuel filter housing, a local weld line right beside a thread
hole was looked into (shown in Figure 1 and Figure 2). Since it is the area that
will bear the most amount of stress and torque, the existence of weld line is
most likely to cause failure under operation. The minimum gap angle value of
that weld line versus varying melt temperature is detailed later in the section.

Figure 2 Local Weld Line being Studying

Figure 3 Zoomed View of the Local Weld Line

Volumetric shrinkage was presented by the percentage of shrinkage relative

to its original volume (Figure 3). Maximum shrinkage rate under each melt
temperature was compared to derive their relation. Parts quality result is also

presented in percentage, based on the mechanical properties and

appearance of the part (Figure 4).

Figure 4 - Volumetric Shrinkage

Figure 5 - Part Quality Percentage

Data of local weld line angle, maximum shrinkage rate and quality
percentage gained from simulation is shown below table. Diagrams of each
features trend versus melt temperature is also included. Melt temperature
range and value selection was based on the injection molding guideline of

Isoplast 301 published by Lubrizol

(Isoplast Processing Guidelines Lubrizol n.d.).
Table 1 - Data of Part's Features

Melt Temperature
( C )

Local Weld Line

Angle

Max Quality
Percentage (%)

( )

Max Shrinkage
Rate
(%)

230
232.5
235
237.5
240
242.5
245
247.5
250

34.4
23
27.4
22
26.3
23.5
35.4
20.8
34.4

5.308
5.421
5.541
5.647
5.764
5.854
5.904
6.022
6.112

0.80
71.8
71.8
71.9
71.9
71.9
72
71.9
71.9

Figure 7 - Weld Line Angle vs. Melt

Temperature

Figure 8 Volumetric Shrinkage vs. Melt

Temperature

The results show a clear trend of maximum shrinkage versus melt

temperature as melt temperature goes up, volumetric shrinkage increases
accordingly. This result accorded well a previous study: as the temperature
discrepancy between melt temperature and mold temperature goes up with
higher melt temperature, the shrinkage during cooling is more furious due to
entropy effect (Jansen, Van Dijk and M.H. 1998).

On the other hand, quality percentage of the part experienced a sudden rise
when melt temperature went up from
Figure 9 Quality Percentage vs. Melt
Temperature

230

to 232

C , and remained at around 70% after that. It indicated

that there existed a certain threshold of melt temperature, above which part
quality percentage was stable around a value.
However, weld line angle didnt show a clear relation with melt temperature.
The angle value fluctuated around 28 , and the amplitude increased as
melt temperature went up. This random trend accorded well with Zhais &
Manjunathas research into weld line formation, both stating that weld line
formation is heavily depended on gate position and runner size, while melt
temperature and mold temperature is much less important (Zhai, Lam and Au
2006), (Manjunatha and Ramesh Babu 2014).

Effect of Mold Temperature

Likewise, mold temperature also plays an important role in injection molding
process. To understand the influence of mold temperature, we fix the melt
temperature at 230 C , maximum machine pressure at 95 MPa, and make
the injection time auto-adjusted by Moldflow, and then we change the mold
temperature form 66 C

to

87 C . The results are shown in the Figure

10. In terms of injection pressure variation, increasing mold temperature

causes less pressure variation, which is better for the injection process since
large pressure difference in the same mold cause uneven shrinkage rate.
Also, it also shows higher mold temperature requires less maximum pressure
provided by machine, requiring less machine power. However, increasing
mold temperature also causes negative effect on fill time. It ends up with
needing more time in manufacture process. As to quality and weld lines
angle, it shows the better mold temperature is below 72 C . It shows zero
high-quality percentage and irreverent influence on minimum weld line angle
above 72 C .
Most engineering problems are trade-offs between factors. Depending on
which factor is critical to the problem, engineers tend to sacrifice less
important factors. For example, in our case the production efficiency is more
important than small pressure variation, we recommend setting mold
temperature at lower point such as 70
and vice versa.

so that the fill time is reduced,

injection pressure variation v.s. mold temperature

11
10.8
10.6
10.4
10.2
10
9.8
9.6
9.4

(a)

(b)
fill time v.s. mold temperature

1.75
1.7
1.65
1.6
1.55
1.5
1.45
1.4

quality percentage v.s. mold temprature

1
0.8
0.6
0.4
0.2
0

(c)
weld line angle v.s. mold temperature
40
30
20
10
0

(d)

Figure 10 influence of mold temperature on (a) fill time (b)quality

(c)injection pressure (d) weld line angle

References
[1] Akbarzadeh, Alireza, and Mohammad Sadeghi. "Parameter Study in Plastic Injection Molding
Process Using Statistical Methods and IWO Algorithm." IJMO International Journal of Modeling
and Optimization(2011): 141-45.
[2] Farshi, Behrooz, Siavash Gheshmi, and Elyar Miandoabchi. "Optimization of Injection Molding
Process Parameters Using Sequential Simplex Algorithm." Materials & Design 32.1 (2011): 41423.
[3] Ahmad, A.h., Z. Leman, M.a. Azmir, K.f. Muhamad, W.s.w. Harun, A. Juliawati, and A.b.s.
Alias. "Optimization of Warpage Defect in Injection Moulding Process Using ABS Material." 2009
Third Asia International Conference on Modelling & Simulation (2009)
[4] Lei Xie, Study on relevant factors influencing the strength of weld line defect in micro injection
molding process, July 2010, doctor dissertation
[5] "What to Do About Weak Weld Lines : Plastics Technology." What to Do About Weak Weld
Lines : Plastics Technology. N.p., n.d. Web. 01 Dec. 2015.
[6] "Coping with Weak Weld Lines : Plastics Technology." Coping with Weak Weld Lines : Plastics
Technology. N.p., n.d. Web. 01 Dec. 2015.

n.d. Isoplast Processing Guidelines - Lubrizol. Lubrizol. https://www.google.com/url?

sa=t&rct=j&q=&esrc=s&source=web&cd=2&ved=0ahUKEwjas4yZn7rJAhUCoogKHX
NFAnIQFggjMAE&url=https%3A%2F%2Fwww.lubrizol.com%2FLife-Science
%2FDocuments%2FMedical-Polymers%2FProcessing-Guides%2FISOPLASTProcessing-Guidelines.pdf&usg=AFQj.
Jansen, K.M.B., D.J. Van Dijk, and Husselman M.H. 1998. "Effect of processing conditions on
shrinkage in injection molding." Polymer Engineering & Science 385: 838-846.
doi:10.1002/pen.10249.
Manjunatha, M., and K. Ramesh Babu. 2014. "The Influence of Gate Location in an Injection
Moulded Basetta Tu Base Component." Int. J. Mech. Eng. & Rob. Res. (Int. J. Mech.
Eng. & Rob. Res. 2014) 3 (3). http://www.ijmerr.com/v3n3/ijmerr_v3n3_58.pdf.
Yang, V., C-T. Huang, P-C Tsai, J. perdikoulias, and J. Vlcek. 2004. "Simulating the Melting
Behavior and Melt Temperature Inhomogeneity in The Injection Molding Process."
http://www.moldex3d.com/en/assets/2011/09/Simulating-the-Melting-Behavior-andMelt-Temperature-Inhomogeneity-in-The-Injection-Molding-Processe.pdf.
Zhai, M., Y. C. Lam, and C. K. Au. 2006. "Runner sizing and weld line positioning for plastics
injection moulding with multiple gates." Engineering with Computers 21 (3): 218-224.
http://link.springer.com/article/10.1007/s00366-005-0006-6#/page-1.